Container and method of making same



Oct. 3, 1944. K STUART ET AL 2,359,335

CONTAINER AND METHOD OF MAKING SAME Filed April 9, 1941 4 Sh =.e1,s-Shee'cl l k. STUART ET A1.

CONTAINER AND METHOD OF MAKING SAME Oct. 3, 1944.

`4 Sheets-Sheet 2 v Filed April 9, 1941 @ttm/nuja.

Oct. 3, 1944. K. sTUAR-T ETAL 2,359,335

CONTAINER AND METHOD OF MAKING SAME Filed April 9, 1941 4 sheets-she@ 3 Oct. 3, 1944. K, STUART ETAL CONTAINER AND METHOD OF MAKING SAME Filed April sa, 1941 4 Sheets-Shet 4 Kimberly 5mm Allen l5. h/sn Patented Oct. 3, 1944 l .A

UNITED STATE-s PATENT oFF-lcs Kimberly Stuart, Menasha, Wis., and Allen B.- Wilson, Evanston, Ill.; said Wilson assigner, by mesne assignments, to Elizabeth B.. B. Stuart, Menasha, Wis.

' Application Aprile, 1941, serial No'. esmas (ci. .22o-5.1)

6 Claims.

The present invention relates to containers and methods oi making them, and more particularly to shipping cartons made of non-metallic sheet material reinforced by strengthening beads of metal or like material.

Although containers of reinforced iibrous material have been heretofore proposed, they have not been wholly satisfactory through failure to stand up under all conditions of service, especially when. heavy goods are vto be transported. Moreover, most oi' them have no appreciable strength unless the cover is tightly closed. In other words, they rely largely for strength upon -a rigidly secured cover. Also, certain metal bound containers oi' the prior art are of complicated costly construction, which rules them out as commercially practical articles, and none oi' them is of suicient strength to render them reusable, as, for instance, in delivery and return handling of beer, milk and other beverage bottles.

It is the major object of this invention to provide novel, low cost, reinforced non-metallic con- A further object is to provide novel apparatus for bending 'rimmed blanks into curved form junction with the annexed drawings, and from the appended claims.

tainers which` are of maximum strength for thev weight of fibre board and the quantity of reinforcing material incorporated in them, and which are so constructed that all of the edges of the board are protected by reinforcing material.

Another important object is to provide a container having a plurality of side walls formed from a single piece of board secured together at its ends and having a stii, reinforcing bead at its top and bottom edgesdesigned to rigidity the container and make it possible to handle heavy articles without serious distortion and also making it sufilciently )rugged for -u turnable milk or beverage case.

A further object is to provide a container hav- 'I ing fiat sides joined by rounded corners, and reinforcing beads 0r rims at the upper and'lower edges ofthe sides .operable to stiii'en and protect the rounded form of the corners, thereby contributing two-fold to vthe rigdity of the conthe edges against scuilng and to also maintain and bottom attaching members, the reinforcing beads beiri'g so applied that, when the container is set up, andl before the top and bottom are applied. thesides and beadsmay be permanently secured in endless relationship.

In the drawings:

Figure 1 is a perspective view of a containe embodying the invention;

Figure 2 isa vertical transverse sectional view through the container of Figure 1, showing the A@parts on an enlarged scale;

Figure 3 is an enlarged sectional view taken lsubstantially on line 3-3 of Figure 2, looking in 'the directionof the arrows;

i Figure 4 is an enlarged frag-mental perspective view of the corner of the container shown in Figure 1, but with the reinforcing band broken away to illustrate the joint between the two ends of the blank from which the sides are formed;

Figure 5 is an enlarged fragmental elevational view illustrating 'the joint shown in Figure 4; and with the hand and its connector in phantom lines;

Figure 6 is a bottom plan view of a corner of the vlcontainer shown in Figure 1, onan enlarged scale;

Figure 7 is an isometric view of the blank froml which the sides are formed and shows the blank with its flanges foldeddown, and with one of the strengthening beads applied;

Figure 8 is a fragmental sectional vviewl of the upper. edge of the container, showing a modied form of closure construction also forming part of the invention; vFigure 9 is an interior view of the container prior to applying the bottom wall, but showsa modied iorm of corner construction of the invention; l

Figure 10 is a side elevational view of the apparatus preferablyv employed to bend the blank into finished fim: y 'Figure 11 is a sectional view taken substantially along the line II--'|l of Figure 10;

Figure 12 is a horizontal sectional view through a hexagonal shaped container forming part of the invention;

Figure 13 is a fragmental with parts `broken away, of a lcontainer embodyperspective view, l I

2 2,359,335 A ng a modied bottom construction also forming part of the invention;

Figure 14 is la sectional view taken on the line Il-Il of Figure 13, looking in the direction of the arrows;

Figure 15 is a fragmental perspective viewv employed to designate like parts through the seva eral views thereof, and referring particularly to Figures 1-7, inclusive, the receptacle of the invention chosen forv illustration is of rectangular shape, for packaging beer bottles or the like,

but it is tobe understood that the invention is not limited to any particular shape vof receptacle and may be advantageously employed for producing receptacles of other shapes and sizes.

The container of the invention embodies flat sides I0, II, I2 and I3 and rounded corners and is so designed as to take full advantage of the Y inherent rigidity and strength of a partial cylindrical surface and embodies reinforcing means for maintaining the cylindrical shape at the corners and for stinening the dat sides of the unit,

and for'also protecting the edges against scufiing or other damage incident to rough handling in 35 so as to form endless reinforcing beads at both use. Ahinged top or closure il and a bottom I complete the container.'

The sides are preferably formed from a single length of material of any desired character, for

instance fibre board of requisite weight. Referi A 40 tom member I5, having rounded corners 23, is inserted from the top and secured in place on the v ring to Figure '1, which' illustrates a blank opened out, the blank-terminates at one end in a square Vedge I3 and at the other ina flap II. Flap II tapers into short, transversely disposed surfaces I3, for a purpose that will presently appear.

container form, the opposite edges of the rims will be disposed in abutting relationship.

The blanks are preferably shipped in nat form, with the rims fastened to their opposite longitu- 5 dinal edges. At the point of use, the blanks are folded up into container form, preferably by a roll form of bending apparatus to be hereinafter described, into the form shown in Figure l, so

as tohave four corners 25 of partial cylindrical form. The radius of curvature of the corners may vary` as desired,.but if cylindrical articles are to be packaged, the corners will be given aradius of curvature corresponding substantially to the radius of curvature of the article, so that the V mavimum utilization'of the material of the container may be made. By simultaneously .rolling the sides'and rim members 22 and 23 into partial cylindrical form, the corners maintain their shape and materially contribute to the strength of the unit, since they are inherently stable.

After the blank has been bent into the form lust described,`flap I'I is preferably brought outside wall I3, edges I8 are brought -into alignment v with edge I6, as seen in Figure 4, and flap II is rigidly secured to wall I3 by means of metal I staples 21, but any other suitable fastening means maybeemployed.

With the parts disposed as just described, the opposite ends of rims 22 and 23 will be disposed al) slightly out of' lateral alignment, edue to the o ver- ,lap of flap I I and wall i3. By applying a generally c-shaped coupling member 28 to the ends of rims 22 and 23, they are brought into exact alignment, and are permanently secured together gthe top and the bottom of the container, which imparts rigidity to the unit. 1

' Bottom anges BI`B4, inclusive, are then bent inwardly, as shown in Figures 2 and 6, and botflanges by fasteners '3I or the like. 'I'he bottom is preferably vmade -of heavier weight material than the sides, to give it sufllcient strength to., sus- 'rne blank is also provided with a. plurality of 45 tain hevvloads.

flanges .TI- 'I'l, inclusive, and BI-B3, inclusive, which, as seen in Figure '7, are folded'down fiat against the body of the blank prior to the rimming operation.r If desired, a pair of hand hole V the rimming operation sumcient pressure is applied to cause the'rim t0 bits into Opposite sides of the blank 'adjacent the edge, with the result.

that an extremely strong bond is formed between the rim and blank.y Asimilar rim 23 is applied along the opposite edge of the blank. vThe rim or beads may be simultaneously applied to the opposite edges of the blank in a double rimnling machine, or if .desired the blank may be passed throlllhtbemachinetwicetorimbothedges. A machine whichmaybeused toapply rimming therlmstotheblankisdisclosedin United States '70 Letters Patent No. 2,283,962 of Wilson and Swangren issued Hav 28, 1942. ,InV either event, the rim-forming material is cut toV lie substantially ilush with'edges I3 and I3 attheopposite ends of Bottom I 5, being a separate element, may be made of heavier material than the side walls, and

also may be dimensioned as seen in Figure 2 so that its outer edges overlie rim 23. These features openings 2| may be provided in the blank prior to 50 contribute to make the bottom extremely strongv and able to adequately -support heavy articles such as beer bottles and the like. Also, securing the bottom to flanges running along the four sides of the container strongly reinforces the sides against collapsing tendencies.

A; As seen in Figures 1 and 2, .the flanges running along the top and lower edges of the container 'preferably terminate short of the rounded corners, so that the latter may be smoothly formed @o without binding tendencies and will retain their shape.

Top Il is preferably provided with a flange 32,

which is secured to flange T3 by a plurality of staples 33, the latter performing the dual purpose e5 of securingthe topv to the container and also rigidly securing the three layers of material at the top edge of the container together to form an -V extremely stifl'ened hinging zone. Cover I3 is also provided with a pair of parallel score lines 34 and 3l. so that it maybefoldedthmughapproximately into the dotted line position vshown in Fig- 'ure 2. AA further important feature is to so-dimensi'on cover I4, that when the container is tho'oover willvlie inthe dotted line posiclosed theblangsothaawhenthelatterisfoldedupin 1| tionl3l,asshownlnl*igllre2 ,belowrim22, the

opening movement. The cover ls also provided with an opening 31, and is suiliciently flexible so that a finger may be inserted and the cover bowed suiciently to bring its free edge past rim 22. If

' desired, the width of the cover may also be slightly greater than the distance between the rim 22 of the end walls Ii and I3, so as to be yieldably retained in place below it in a similarmanner.

Seen in Figure 3, hand opening 2| is preferably formed by striking a flap 33 from the body of walls H and i3 and folding it inwardly so as to 11e behind flange T2. Flap 33 may be secured in place by fastening elements passing through the three thicknesses of the material, to form an extremely strong means for handling the container when loaded. If desired, an additional metal clip 39 of C-shape in section maybe clamped in place as seen in Figure 3 to forman even stronger joint.

In Figure 8 there is disclosed a modified form of top construction which may be used in place of one shown vin Figures 1 and 2. In this instance closure I-4a is integrally formed with side wall I2a so that, when it is folded down and rim 22 applied, it may be brought into open position by folding it along `'the score lines 34a, 35a and an additional score line 4i located adjacent the rim. This construction possesses 'the advantage that it is not necessary to secure the cover to the container in a separate operation, but it does not of course possess quite the strength of the one shown in Figures 1 and 2. j

In Figure 9 there is disclosed a modified manner of constructing the corners of the container, embodying a double thickness of material at the The bottom supporting flanges B2-aud` corners. B3 are provided on the blank as before, but in addition a corner blank 42 is left in place on the blank at the top and bottomof each corner, and provided with deep score lines 43 to facilitate bending it into cylindrical shape. Before folding the flanges down against the blank a slot 44 is provided betweeneach flange 42 and its neighboringv flanges. The modified construction is assembled in the same manner as the one previously described, the only diilerencebeing that the oompleted container embodies a flange 42 at each top and bottom corner which remains in engagement with the container walls as shown in Figure 9, and performs the function of providing two thicknesses of material Awithin rims 22 and 23 all around the container, including the corners and may be desirable in certain instances.

Referring to Figures 10 and 11,'we have disclosed the preferred form of apparatus for bending the container blank into ilnal form. It comprises a pair of rollers 46 and 41 adapted tobe moved together to clamp the container blank between them. Roller 46 is stationarily'supported while roller 41 is mounted for rotation by any s uitable means (not shown). The rolls are provided with grooves 48 and .49, spaced apart a distance equal to the spacing of rims 22 and 23. The pairs of grooves are so alignedand are of sufhcient depth to receive the. rims as seen in Figure 10 and are preferably so designed that when the rolls are brought together the walls ofthe grooves bear upon the rims and the surface of the rolls bear shown in Figure 11; and then giving roll 41 a counterclockwise planetating motion about the vaxis of roll 46 as indicated bythe arrow in Figure 11, to smoothly bend the 'blank and beads into curved form. By reason of the grooves in the bending surfaces, the blank is held in the proper positionA with respect to the rolls, and also collapse of the beads during the bending operation is avoided.

As seen in Figure 1l, the rolling operation has been completed, providing curved walls 25 and the corresponding bends in rims 22 and 23, roller 46 having a radius of curvature substantially equal to the Vdesired radius of curvature in the finished, corner.

Although the bending members have been illustrated as taking the form of rollers 43y and 41,.

it is to be understood that roller 46 may be replaced by a member having a curved grooved surface, and roller 41 replaced by a ilat` plate having grooves matching those in the member, and the plate and member manipulated relatively to wipe the blank around the corner of the stationary member, and the appended claims are intended to embrace the invention when it assumes this form.

In Figure 12 there is disclosed a container of irregular hexagonal shape, especially designed yfor packaging articles of generally cylindrical shape with a minimum of voids =between the articles and a minimum of ivoids between the articles and the container, which makes it possible'to employ a minimum amount of material for packaging them.

The container is made in the same way as the one previously described except that the blank is`formed to have six rather than fourssides, and the shapes of the top and bottom are changed accordingly.

The container is provided with four Walls 5I,

upon the container simultaneously, and yet avoid 52, 53 and 54 of equal width and a pair of wider walls 55 and 56, which are of equal width and disposed parallel to each other. An overlapping joint 51, similarv to the one previously discussed in connection with Figures 1 to '7, is formed in wal155.

We have found that by giving the container the shape illustrated, and providing it with rounded corners 25a, twenty-four cylindrical articles may be accommodated in a space materially smaller than if the container were given any other shape. For instance, compared with the rectangular container accommodating f our rows, with six articles in each row, it cuts the material by almost 20 percent. It is also to be understood that, by following this disclosure, other unsymmetrical hexagonal containers may also be developed for economically packaging more or less than twenty-four articles, and the appended claims are intended to embraced the invention f when it assumes those forms. Also, the articles may be stacked two or three high and the advantages of the hexagonal container still fully utilized.v

In Figure 13 and 14 are disclosed further modified top and bottom closure constructions of the invention. In Figures 13 and 14 the upper and lower edges of the container side walls terminate in straight edges and the beads are applied after the container is set up, in a manner to be hereinafter discussed in connection with Figures 16 and 17.

After the container is set up and staples 21 applied to hold; flap i1 in position, a bottom member I5a, cut away'to provide rounded corners so as to tightly grip the side walls, and

6|, and -four flaps 62, is inserted inthe bottom of the container into Athe position shown in Figures 13 and 14, and rim 23a is then applied, so as to firmly clampvflaps 62 against the inner surfaces of the container side walls. 'I'his securely holds the bottom in place, results in rounded corners without causing a pucker, and yetprovides a double thickness of material along the four sides of the container. l

It is to be understood that the closure' constructions of Figures 13 and 14 maybe used at the top and/or bottom of the container. at both the top and bottom, thev container bottom'will first be securgd'in place, the container will then be turned upright and loaded with its contents and the top then secured in place, either by a rimming operation, as shown in Figures 13 and 14, or by a stapling or stitching operation. If it is not desired to permanently secure the top in place, the closure constructions of Figures 1 and 8 may be used in combination with bottom closures constructed in accordance with Figures 'A or shell cases and also -various kinds.

When used 13 and 14, as for instance when used in,l returnable beverage bottle service.

In Figure l5 we have shown a modified tcpI closure construction split into two sections 65 and 66, and having deep ilanges 61 and 68, re spectively. Closures 65 and 66 may be hingedly secured to the container in the manner shown in either Figure 1 or Figure 8, and the flanges are designed to divide the contents of the container into two equal parts. For instance, if it is a bottle container, flanges 61 and 68 will fit down between the necks of the bottles, dividing them into two equal parts and making it possible to open onehalf of the. container at a time without disturbing the remaining bottles. Also, the flanges provide a stifiened zone extending down the middle of the container, when the latter is closed, ma-

terially adding to the rigidity thereof.

Although the blanks preferably have the rims in Figure 7, for instance, when they are to be shipped some .distance and the customer is not equipped to apply beads, under some circum-` stances it is desirable to apply the rims| at the time of setting up the container, and in Figures 16 and 17 we have shown one way in which it may be carried out.

The blank, without beads 22 and 23 of Figure 7, is folded up into container form, and staples 21 applied to secure flap l1 in place over side wall I3, as previously described. The top and bottom edges of the container are then successively passed between a. pair of rolls 69 and 1| so as to crimp a metal strip in place ereon.` 'Ihe strip is bent into C-shape in cross ection.

imulapplied thereto prior to setting them up, as shownl may be shipped in knocked down state and set up and completed by the user in one of two ways, either of which results in a sturdy container for the packaging of comparatively heavy materials of all kinds, among which may be lmentioned beverage bottles or cans, canned goods, cartridge 'I'he invention may be embodied in other specic forms without departing from thespirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive,v the scope of the invention being indicated vby the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

What is claimed and desired to be secured by United States Letters Patent is:

1. A container having aplurality of side walls and a bottom, said side walls being formed ofva single length of sheet material bent transversely at a plurality of longitudinally spaced regions to form a-multiplicity vo1' side walls, each pair of adjacent side walls being joined by a curved corner, and said length of sheet material having its ends secured together, the bottom edges of certain of said side walls having inwardly directed flanges which extend 'along the edges of .said certain side walls toward, but terminate short of, said curved corners; and means for securing said bottom to said anges.

2. A container having Aa plurality of side walls `and a bottom, said side walls being joined by corners of parti-cylindrical form, and being made 3. The container construction defined in claim` 2, wherein said bead is ofc-shaped form in transverse section and has its opposite edges tightly gripping the side walls of said container and said flanges. Y i A 4. In an article of manufacture, a container of box-like form, comprising a plurality of upright taneously circumferentially curved around the container to provide closed rim 23h, having its ends overlapped at 12, and tightly gripped to.

gethen This eliminates .the need lfor coupling members 28 used in Figure 1 and providesv end- 'allelto thentlrgins side walls; a bottom; and a top, said side walls being formed of a single length of material bent transversely at a plurality of longitudinally spaced regions to form said side walls and having its ends overlapped and secured togethen'to pro- ,videy a container having a plurality of flat side wall portions joined by curved corner portions; a strip of reinforcing and secured to the and said corner portions; a strip of reinforcing material extending along and secured to the lower edges of said side walls of the container: a bottom closure member; and means vfor securing said closure member to said container, spaced above the level of 'the lower edges thereof, comprising means extending along each of said side walls interlorly thereof and having zones of securement to said closure member extending along and paroi' said closure member. said rectangular articles of material extending along upper edges of said side walls V zones of securement terminating at each end short of said curved corner portions, whereby said Y closure member is secured to said side walls and o der around said one end of the container; a plurality of flaps extending along said one edge of said side wall interiorly of said container and being tightly gripped by one longitudinal edge of said reinforcing bead, said naps being .bent out wardly from the plane of said side wall immediately adjacent said one longitudinal edge of the bead, so as to form ilanges projecting inwardly from the inner surface of the container side wall in overlying engagement withthe marginal shoulder formed by the bead; and means for sercuring said closure to said anges. said closure seating directly upon said flanges and extending outwardly in sufllciently -close proximity to said container side wall as to marginally overlie said marginal shoulder. whereby any outward forces acting upon said closure are transmitted directly to said bead.

6. In a container having a one-piece side wall and a separate closure for one end of said container, a blank for manufacturing said container comprising a single length of flexible, fibrous sheet material having a length approximately equal to the perimeter ofthe container side wall and adapted to be bent into hollow form' and have its ends secured together to form the entire side wall of the container; a metal reinforcing bead extending continuously along substantially the entire length of one longitudinal side edge of said .blank and being rigidly secured thereto, said bead being of generally C-shape inv cross section and enclosing said' one side edge of said blank, said blank also embodying a plurality of longitudinal iiaps lying fiat against one side of the4 blank along one edge of said blank and being tightly clamped against the blank by one longitudinal edge of said reinforcing bead. said flaps being adapted to be bent koutwardly from the plane of said blank so as to form flanges projecting inwardly from the inner surface of the container side wall after the blank hashad its ends secured together, to provide supports for said container closure.

mmERLY STUART. ALLEN B. WILSON. 

